LT230 intermediate shaft-talk to me - Defender Source
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  #1  
Old July 19th, 2010, 12:07 PM
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LT230 intermediate shaft-talk to me

I have a noisy 1.4 of 1997 vintage and I have a 1.2 lt230q from the same year NAS spec truck .
The 1.2 is in the truck and is nice an quiet but the gearing is too tall. Both of these should have 28 tooth input gears and I want to open the tcase and change the gears on the intermediate shaft/pin. I looks as though I need a crush sleeve and new self locking nut. I have never opened one of these and have no idea how difficult or easy this may be. Can someone shed some light ? About to change the clutch this week and while I'm there...
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  #2  
Old July 19th, 2010, 12:11 PM
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I am in nearly the same boat Doug, I am dropping my t-case to swap over to 1.4 gears myself, so I am interested to hear the answer as well.
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  #3  
Old July 19th, 2010, 12:42 PM
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I have read the rebuild manual (http://dividingcreekroverimports.com...erhaul_manuals) and it appears that the crush sleeve, 2 "o" rings, and the main sump gasket are all thats involved. If the gears are inter changeable you undo the main shaft nut, pull the shaft, & remove the gears. You pop out one of the bearings, put in a new crush sleeve in the gears going in and put it back together. The getting pre load right and knowing if the 1.4 gears I have will work in the tcase I have are my quandrys. Sound's like Randy may know.
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  #4  
Old July 19th, 2010, 12:47 PM
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You make it sound like the t-case doesn't have to come out. Is that the case???
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Old July 19th, 2010, 12:56 PM
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The only thing I've ever seen on the intermediate shaft is a bearing spacer, they range from like 58.3 to 59.3 MM. To change this you need to use a height gage to measure the new vs old stack height of the intermediate gear (with bearings) and get the right spacer from the dealer. Then using a torque meter turn the main shaft with it all installed and check the torque to turn (should be about 19 inch pounds (?).
To be honest I've never done any of this but I stayed at a holiday inn last night. The last T Case I buit was using Maxidrive gears and the procedure is totally different. Prior to that I've only changed bearings so I didn't worry about the spacer.
IIRC the only two components that need to "adjusted" when swapping gears is the preload on the intermediate gear bearings and the preload on the input gear bearings using shims after measuering end float..
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Old July 19th, 2010, 12:56 PM
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Not sure about that. The intermediate shaft has to slide out to the front of the case. I don't know if the linkages etc will be in the way or not. The floors come right out on my truck (removed them 3 times recently and had them line x'd etc) so it might be doable with all that access from above. Moot point since I have to replace a blown clutch disk that won't dissengage, my t case has to come out any way.
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Old July 19th, 2010, 01:00 PM
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Crush sleeve in place of the bearing spacer? That certainly does speed things up.

------ Follow up post added July 19th, 2010 05:02 PM ------

Hey Doug,

Is my truck out of jail yet?
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Old July 19th, 2010, 01:06 PM
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Thumbs up

Quote:
Originally Posted by revor View Post
Crush sleeve in place of the bearing spacer? That certainly does speed things up.

------ Follow up post added July 19th, 2010 05:02 PM ------

Hey Doug,

Is my truck out of jail yet?
Funny, I was on the phone holding asking the same question. Yes it was cleared this morning (week?).
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Old July 19th, 2010, 01:12 PM
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When can I have it !?!?!?!
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Old July 19th, 2010, 01:48 PM
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I'll have it tomorrow. You can wind DAS up accordingly. Did you want me to keep that galvanized frame and just send the rest on ?
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Old July 19th, 2010, 03:29 PM
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Cool!
I'd like to keep the frame Doug, it sorta holds the rest of it together


Quote:
Originally Posted by 130Tdi View Post
I'll have it tomorrow. You can wind DAS up accordingly. Did you want me to keep that galvanized frame and just send the rest on ?
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  #12  
Old July 19th, 2010, 05:11 PM
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Doug. You just remove the big nut and tap out the shaft... Inside is the bearings and crush sleeve. reinstall with new crush sleeve... as per manual..
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Old July 19th, 2010, 05:30 PM
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Thanks Randy. Did you do it with the tcase in the truck ?
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Old July 19th, 2010, 05:55 PM
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I talked to Les at RN and confirmed it can be done in the truck, but it's obviously a little challenging. Just ordered the nut, crush sleeve and seals.
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Old July 19th, 2010, 07:20 PM
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Did it out of the truck.. I guess it can be done in the truck but will be a pain in the ass for sure..
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Old July 20th, 2010, 03:52 AM
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Hi,

all 1.410 LT230's have 26 teeth on the input gear, the 1.2's can have 26, 28 or 38,

if you can advise both serial numbers I will let you know if they will swap,

you cannot remove the intermediate pin in situ, the head of the pin is half covered by the gearbox so will not come out,
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Old July 20th, 2010, 06:47 AM
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Quote:
Originally Posted by ashtrans View Post
Hi,

all 1.410 LT230's have 26 teeth on the input gear, the 1.2's can have 26, 28 or 38,

if you can advise both serial numbers I will let you know if they will swap,

you cannot remove the intermediate pin in situ, the head of the pin is half covered by the gearbox so will not come out,
The pinheads are different in Vermont
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Old July 20th, 2010, 09:06 AM
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Quote:
Originally Posted by ashtrans View Post
Hi,

all 1.410 LT230's have 26 teeth on the input gear, the 1.2's can have 26, 28 or 38,

if you can advise both serial numbers I will let you know if they will swap,

you cannot remove the intermediate pin in situ, the head of the pin is half covered by the gearbox so will not come out,
Thanks Dave. I'll take you up on that-good to know on the input gear.
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Old July 20th, 2010, 05:56 PM
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My T-case serial is 28D134116D. That 28D better not refer to the tooth count!
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  #20  
Old July 21st, 2010, 05:54 AM
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Originally Posted by Wolf Fabrication View Post
My T-case serial is 28D134116D. That 28D better not refer to the tooth count!
the 28 refers to the gearing being 1.2 ratio,

all 22D 1.410 ratio LT230's had 26 teeth

the 28D upto 28D308626E had 26 teeth

the 28D from 309143E to 551442F has the 28 tooth input gear
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